Production Loss Analyst
Finds the ninety-second stops nobody writes down
OEE is 68.8%: 31% of planned time was lost, mostly to slow running.
8 machines, 38,400 planned minutes. Availability 90.6%, performance 77.8%, quality 97.9%.
Lost time: 3,630 min to stops, 7,805 min to slow running, 554 min to rejects.
Labeller L1 is the weakest at 59.4% OEE; 8 of 8 machines are below the 85% world-class benchmark.
85% is a commonly quoted benchmark, not a target for your plant. Why machines stopped is not in the data. A performance above 100% is capped and points to a wrong ideal cycle time.
Planned time: productive and lost
- Productive time69%
- stops9%
- slow running20%
- rejects1%
OEE by machine (%)
Lost minutes by machine
- Labeller L11947
- Mixer M11,650
- Filler F11,580
- Capper C11,485
- Press H11,373
- Packer P11,345
- Sealer S11,324
- Palletiser T11,284
Machines, weakest first
| Machine | Availability | Performance | Quality | OEE | Biggest loss |
|---|---|---|---|---|---|
| Labeller L1 | 94.2% | 68.5% | 92.1% | 59.4% | slow running |
| Mixer M1 | 91.3% | 72.6% | 99.1% | 65.6% | slow running |
| Filler F1 | 89.2% | 76.3% | 98.6% | 67.1% | slow running |
| Capper C1 | 93.5% | 74.8% | 98.7% | 69.1% | slow running |
| Press H1 | 94.6% | 77.1% | 97.9% | 71.4% | slow running |
| Packer P1 | 81.5% | 89.5% | 98.7% | 72% | stops |
| Sealer S1 | 92.7% | 79.1% | 98.8% | 72.4% | slow running |
| Palletiser T1 | 87.5% | 84.3% | 99.3% | 73.3% | slow running |
What to do this week
- Start with Labeller L1: biggest loss is slow running (1947 min in the period).
- Target slow running across the line: it is the largest of the three losses (7,805 min).
Do
- Take the single biggest loss on the weakest machine and find its top three causes.
Don't
- Don't compare machines with different products on OEE alone: ideal cycle times differ.
How to improve
- Add stop reasons so the next report can rank downtime causes.
- Add product and changeover times so the next report can separate changeovers from breakdowns.
Demo
Overview
Manufacturers measure overall equipment effectiveness and then argue about the number instead of acting on it. It is the product of three things — availability, performance and quality — and reporting the product hides which one is costing you. A line at 62% could be stopping constantly, running steadily below rate, or producing scrap. Three problems, three owners.
The loss that dominates almost every line is the one nobody logs. Breakdowns get recorded because somebody has to be called. Short stops — a jam, a changeover overrun, a wait for material, ninety seconds at a time — are not worth writing down individually and are collectively larger than every breakdown combined. They appear in the data only as the gap between what the line should have produced while running and what it actually produced.
That gap is computable from records every plant already has, and it is where the money is. It is also why "we need a new machine" is usually the wrong conclusion: the machine is fine, it stops for ninety seconds forty times a shift, and nobody has added it up.
This agent computes that gap, splits every loss by cause, and prices each in units and hours so the largest one is obvious. It changes no setting and touches no machine.
Benefits
Capacity found without capital
Most lines have a shift's worth of output inside their own losses.
The right problem, with an owner
Maintenance, operations or quality — the split says which.
The machine you did not need to buy
Which is the usual conclusion when the gap is finally added up.
What it does
Computes the losses nobody logs
Short stops are individually too small to record and collectively larger than every breakdown combined. Visible only as a gap.
Splits the number instead of reporting it
Availability, performance and quality are three different problems with three different owners.
Prices each loss in units and hours
So the argument about the percentage ends and the largest loss is simply obvious.
Separates changeover from breakdown
One is a process you control and one is a failure. Merging them buries the fixable half.
Checks the rate itself
A line running at 100% of a rate set optimistically in 2019 is not running well.
Touches no machine
It reads records. It changes no setting, rate or schedule and has no route to any control system.
What this changes
What this changes about your week
- It takes over
- Working out where a shift's available time actually went.
- Done today by
- Argued about in a production meeting from a single percentage.
- How often
- Weekly, and the same argument each week.
- Typical manual effort
- The losses that dominate are never logged, so they have to be computed as a gap.
Why Manufacturing in particular. Short stops are individually too small to write down and collectively larger than every breakdown combined. This is why 'we need a new machine' is usually wrong — the machine stops for ninety seconds, forty times a shift.
Runs unattended
Started by you or by an event, and it finishes on its own. Nothing waits for someone to be at a desk.
The same standard every time
The two-hundredth item is held to the bar the first one was. Consistency is the part people cannot sustain.
It cannot act on its own
Production Loss Analyst has no path to sending, spending or committing. That limit is why its output is safe to act on.
How it runs
This agent runs server-side through the PROMIVO runtime. Each run is logged step by step and every tool call is permission-checked before it executes.
- 1InputValidated against the agent input schema
- 2Modelclaude-opus-5 with automatic fallback
- 3Toolsextract_structured_data
- 4PermissionsRuns READ actions automatically; anything higher waits for approval
- 5OutputStructured result matching the output schema
- 6LoggingTokens, duration and every step recorded
Requirements
Integrations
No integrations required.
Before you start
- Planned production time per shift or run
- Logged downtime with reasons
- Units produced and rejected
- Standard rate per product or line
- Requires the All-Access plan or higher
Use cases
Weekly production review
Where the shift actually went.
Before a capital request
Whether the capacity is missing or hidden.
A line that misses target
Which of the three losses is responsible.
Comparing shifts or lines
On comparable measures rather than on totals.
Pricing
All-Access
Billed monthly through your PROMIVO subscription. Cancel at any time.
Runs consume your plan allowance for agent executions and tokens. See plan limits
FAQ
Do we need sensors on the line?
No. It works from production records — planned time, downtime logged, units produced, rejects. The unlogged losses are computed as the gap, which is exactly why they are findable without new instrumentation.
Does it control any equipment?
No. It has no route to any control or automation system and changes no setting, rate or schedule.
What if our standard rates are wrong?
That is one of the findings. A line at 100% of a rate set optimistically years ago is not performing well, and it reports where the standard itself looks unreliable rather than trusting it.
Reviews
Reviews open once customers have run this agent.
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